Diamond-tipped tool and method of making the same



Nov. 21, 1944- J. TAEYAERTS ETAL 2,363,272

DIAMOND TIPPED TQOL AND METHOD OF MAKING THE SAME Filed July 10, 1942INVENTORS. Jzfl/jzlgya eria. BY jffa gw 'elc/ce,

described and as -a result a new Patented Nov. 21', 1944 2,363,272"DIAMOND-LTIPPED TOOLAND METHO MAKING THE SAME;

Jan Taeyaerts, villa Park, a

, Chicago, 'Ill;

Magnus Toelolte,

ApplicationJuly- 10, 1942, Serial "No. 450 402 16 Claims. (o1. 125-.-39' The invention relates generally to tools tipped with cutting or:abradingelements permanently,

embedded therein, and more particularly to'the' method of making toolsof that character.

general object of the invention is to provide 'anew and improved methodofthe character and improved tool." q It isa more particular object ofthis invention to provide a new and improved method-permittingthe'ernbedding or setting of the diamond or other cutting "element withthe highest precision;

Another object of theinvention is to provide a method of such greatlyimproved and simplified technique asto' permit the accurate setting ofthe cutting" element "with greater precision but in'less titneand withless skilled labor thanhere tofore. I

Z'Stillanother' object is. to provide a new and improved method of thecharacter described whichpermits the employment of a solder as 7 hard asa solder'can be made and still'fiow.

A further object isto provide a method ofthe character described inwhich the're'is -.no wastage ofsolder Land in which the cutting orabradin'g I elementis' at-no time exposed to a direct flame.

'Q'fihEIfObjGQtS" and-advantages will become a parent from the followingdetailed 'description, taken in connection with drawing; in whichz' pFig; 1 is asideelevat'ional view of acompleted singlegdia'mond" tippedtool made by the method and embodying the features of this invention."fjFi'g. '2 is'an enlarged view partially in diametrica'li'section' .atright angles to the plane of Fig. 1; andishowingthe tool inanintermediate stage in the, method of manufacture.

Fig. .3 is a view similar to Fig. 2 but showing the tool instill-adaterstage in the manufacture. Fig. ,-4 is a view similar to Fig. 2 butshowing toolcompleted save for cleaning and finishlug.

Fig-.15 is an enlarged view partially in diametrie calsectionaalong theline 6-4 ofFig. '7; showing in a stage comparable to Fig. 2amultip1ediaithe accompanying-- shank. ,Thi's recess ll; is justsli'ghtly larger in nection with tool's only; It: is" not intended,howeventhatthe 'rnethod be 'limited'inits appli-x cation t'o thelt'wotools shown. On the'contrary;

itis intended to cover the method as adapted to any r tools and 1 manymanner falling within the stint: and .sco'pe of the-invention a's''defined in theappended claims.

For exemplary purposes;-the{invention wi1lfirst be described as;employed in 'themanufacture of atool havihgbut a single cuttingorabradi-n'g e1e-' -ment embedded therein, such as the-toolshown in Figs.1* we. Such a tool commonly has a holder onshank lflformed from a solidrod of iron'orsteel. In accordance with the invention; thisshankisfirstdrilled axially to form as'mall recessjl'l opening throughone end or 'face'of the diameter than themajor transverse dimension" ofthe abrading 'elementher shown as a diamond liftto be insertedtherein',' landpreferably also is shallower than 'themajor orlongitudinal axis of the d'iamondby theexten'tto which the diamond istolproject from theshan'k 'IU when'th'e tool is ccmpletedIfNext.a'sniallielateral passage l'3jis' drilled-in thefls'hankl ."Ih'is'passage: preferably opens at its inner end-to.thebottom.oithereces's-l.l andsextends radially putwardl'y' and somewhat downwardly, asclearly seen in eachof Figs. 2130 4.: Thisxpassage serves both-as -a-; dra=inin assage and-also asa feeder passage, as. will laterbecomeazmoreapparent; p w

With-the shank I'D thus formed with the recess H andvthe passage 13, itis-suitably' supported usuallyand -,preferably,in upright position, asshown=in.Figs;;2 to 4,-in'-preparation for the par tial' embeddingpf thediamond in a--first-;-temporary holding'mediumm This l-temp orary,holding medium; prefer-ablyis one-that is readily/made substantially tofill the recess ll, onethat-in its,;set' condition is not completelyrigid but. remainssomewh'at plastic; and which by; the applicationofheat may-lie liquified on even vaporized mend tipped tool manufacturedby the method :of

this -'in-vention./

Fig. G'is: a" View similar to Fig. 5 showing the tool: completed savefor cleaning and finishing.

- Fig; '1 is anendelevationalview of the tool of Fig..: 6;. e I Whilethe 'method of this-invention is applicabletoa large variety and type oftools, it will, for purposes of d'isclosure; herein be described incontofacilitate .remova-L, Among the compounds v suitab1e;-.and intact thepreferred compound,

is wax,'which is then flowed into thei-recessvtl as represented; by the.reference' character :14. Before-the" wax :sets; .theidi'amondi I 2115"inserted into th'e Jwax-in 'ithe' recess .iinaaproper centered positionwith "the desiredf'point projecting out of the: wax and" out oftherecess;' and:a1se"with the diamo'nd projecting to the desiredciegr'ee to tvhi ch it will proj ct"froin the finished-"tool. Where'possiblef e deptn of the r'ec'es l; as aiready' stateu, is s6 gagedthat"when the dies bear mond is inserted in its desired position theinner tip thereof will rest in the apex I of the recess formed by thedrill. The diamond I2 is held in this position until the wax or othercompound l4 sets. After the wax is set, the tool in this.

thousandths of an inch correction that may be necessary. It will beapparent that this centering may be done leisurely and hence to thecomplete satisfaction of the artisan, because there is no necessity ofcompleting the adjustment before a soldering compound hardens intofinal,

immovable position, as was the case in the old practice where thediamond was initially placed into molten solder filling the recess. Aprecision and accuracy of the very highest degree and far beyondanything heretofore obtainable thus results.

When the diamond I2 is finally centered, it will,

of course, be held in position by the wax I4. The tool is then removedfrom the lathe and any wax that has overflowed the recess II ispreferably cleaned off of the end of the shank II) and the tool ,is thenagain secured in upright position. There is then applied to the end ofthe shank II) a generally cup-shaped mold I6 which is conveniently andreadily formed by the application to the end of the shank of a strip ofstiff tape I'I. This strip of tape is applied so that it projects agoodly distance beyond the end of the shank I0 and even beyond theprojecting tip of the diamond I2. With the mold thus formed, conditionsare proper for the next step in the method, namely, the embedding of theremaining projecting portion of the dia mond in a second, temporaryholding medium. This second, temporary holding medium should be a heatresistant compound and usually is an investment compound, such asplaster of Paris. The mold is completely filled with this invest mentcompound, indicated by the reference character I8. This investmentcompound will, of course, surround and grip the portion of the diamondprojecting out of the wax and thus will serve to hold the diamond in thesame precisely adjusted position in which it is held by the wax. Thetool is now in that stage illustrated in Fig. 2, and at this stageslight pressure is brought to against the investment compound I8 throughsome suitable means diagrammatically represented at 2I to hold the samemore or less tightly against the end of the shank ID.

The first temporary holding medium is now removed, in this instance bythe application of heat to the end of the tool to liquify and vaporizethe wax I4 which is then either absorbed by the porous investmentcompound I8 or flows out through the downwardly inclined passage I3,leaving the entire recess II, and hence all of the space about theportion of the diamond within the recess, free and open for thereception of a permanent holding medium in'which the diamond is finallyand permanently set. This permanent holding medium is, of course, ametallic compound, such as various well known types of solder. The toolis now in the stage illustrated in Fig. 3, but while the wax I I hasbeen removed the diamond is still, through the medium of the investmentcompound I8 which had previously been cast about its projecting tip,firmly retained in the exact, same position to which it was previouslyso precisely and accurately adjusted. The investment compound alone isefficient to hold the diamond in its adjusted position. However, ininstances such as that here illustrated, where the depth of the recessII has been so accurately gaged that the inner tip of the diamond restsin the apex I5 of the recess, additional support for the diamond is thusprovided, thus further assuring that the diamond will not be displaced.

When 'all of the wax has been burned out of the recess II, and while theshank II! is in this heated condition, a ribbon or rod of solder,indicated at 22 in Fig. 3, is fed through the passage I3 where it meltsfrom the'heat of the shank I0 and, by. the pressure caused by thecontinued feeding of the rod into the passage I3, caused to flowcompletely around the diamond I2 and completely fill the recess II, aswell as the passage I3. The rod of solder is fed into the passage I3until it is forced outwardly of the recess between the end of the shankIll and the investment compound I8. This will be visible to the artisanbecause the strip of tape I'I will have been burned off by theapplication of the torch to the end of the tool during the burning outof the wax I4, and is an accurate indication that the recess II has beencompletely filled with the solder. It is to be noted that even theformation of air pockets in the recess is prevented by this method. Withthe solder being fed upwardly from the bottom of the recess, it will asit rises in the recess drive ahead of it any air that may be in therecess, and this air will escape through the porous investment compoundI8. After the solder has solidified, the investment compound I8 isbroken away and the tool appears as shown in Fig. 4, with the recess IIas well as the passage I3 now completely filled with the solder, hereindesignated I9. A thin layer of solder 20 will also overlie the end ofthe shank Ill. The tool is now complete save for cleaning and finishing.Usually the shank is rounded or tapered, depending upon the purpose towhich the tool is to be put, so that in its final form it will appear asshown in Fig. 1.

It is believed apparent from the foregoing that the method is highlyadvantageous over the methods heretofore employed. As already stated,much higher precision and accuracy in the mounting of the diamond isobtainable, and this higher precision is even obtainable by less skilledartisans. The method is readily and quickly performed, so as to reducelabor costs and, of course, the reduction in material costs arephenomenal because the high accuracy obtainable reduces to a veryminimum any discards of imperfectly finished tools. The method providesassurance not only in precision in mounting the diamonds, but

also assures that certain points or facets of the diamond will beexposed and guards against a turning of the diamond during the flowingin of the solder. Moreover, the method requires a minimum of solder andtotally eliminates any waste of solder. The method also avoids anydirect application of a heating flame to the dia mond, and thus obviatesall possibility of burning the diamond, or of removing the polish whichin certain instances is required, and which, of

course, must be applied before the diamond is mounted in the tool. Thispolish can never be reapplied once the diamond is mounted in the deeperinto -the recesses. above stated, positionedin the position which thepassage 13'- a'tool aeainmay'have a solid shank ill of iron "oras'teel.By way of example, the shank I is here 'shown as having a slightlyrounded or curved end=or nose I50", and is also shown as eventuallycarrying five diamonds or other abradaccepts and interstices andupwardly about the diamonds 1i2 f'SolderIiscontinued to be forcedintoth'epassagel- 3"- until: it flows out between the' end of the shank"Hi and the investment compound -'l-8"'-for ming a thin-layer 20" overthe nose oithe tool, as seeni'n Figs; 6 and 7. Throughout the stageorremoval of the waX-and'theinsertion of ing elemen'ts 12', though thenumberfi's not maseen in Fig. 7; a central recess H "would be drilledaxialIy==and centrallyinto theend of the shank l-fl', while theperipheral recesses H' would-be drilled slightly obliquely to the recessl ,'-so"-as to be normal to the slightly curvedend or nose l fi asclearly seen in Figs. 5 and '6. Next a passage -I;3" wou1d be formedwith extensions orbran'ches 13 thereof communicating with the recesses-ll and l I and extending to open out wardly of the shank [0;preferablyslightly downward-1y and externally of the shank, as shown' in Riga-'5and'6;

"The recesses and passage thus formed would next-be filled with asuitable,*first temporary holding medium ld'ysuch as Wax, and into thereoessesithus filled would be inserted the dia- ,,inonds l2-'andhelduntil the wax'had set sufiiciently-to prevent the diamonds from sinkingv The diamonds are, as

theyareintended to have in the final completed "form :of the toolfwhi'chmeans that they are positionedtwith a portion thereof projectingoutwardly o'f the wax and the recesses. The tool is then'supportedinuprigh't position and a cup like mold lfifisis again formed'over theend thereof; Here-again. this mold is readily and conveniently formed bythe attachment of a strip -ofstifi" tape llfl lsurrounding the shank l0.and projecting be-' yond the end of the shank a substantialdistance.Thenmold-is then filled-with a second, temporary holding medium 'I 8,'such as an investment com pound, which of course surrounds and securelyretains therein theproje'cting portion of each of the-' diamonds 12'.After the investmentcompoundhas set, heat is applied to the end of thetool to drive off theWax'M' which either runs out of the passage |3- asa liquid or vaporizes and escapes through the porous investmentcompound. l8. Though the wax is now removed, thev fdiamonds l2 are-keptin the precise position to which they'were adjusted inthe wax, becauseof the support thereof'by the investment compound 18 yet the recesses IIand II" are free and open for: the -reecption of the metallic compound,

' that-is, thesolder in which the -diamonds are eventually'andpermanently set. metallic compound isfn-ow flowed-into'the recessesthrough and 1 conveniently this may be done'by insertingthroughthe-passage l3 a rod .or ribbon of solder. Asit ispushed'through; the passage -13, it is melted by the heat in the shank-lfl and' isfby the pressure or the rod being forced up the passage I 3in turn caused to fill the --re-' cesses l l 'a'nd it" flowingintoall-ofthecorn'ers parting from the spirit and scope within therecesses. After the metallic-compound or solder has set, the investmentcompound l 8"-is broken away and th'e't'ool appearsas shownin- Fig. 6,that is, with-the recesses and the passage filled with metalliccom-pound 19"." The toolisnow finished save for cleaning and pos'sibLyshaping the end of the tool to give it the desired contour. I

It-will be apparent that'there is no difference in the method as appliedto amultiple-diamond tippedtool over themethod as app-lied to a singlediamond tipped tool save in the particular disposition of the recessesand passage and-the fact that the investment compound secures all of thediamonds. Thus it is believed readily apparent that any one skilled inthe art can,'without deof the inven tion apply the method 'to a greatvariety of tools simplyby arranging the recesses-so thatthey meet in acommon point or connect with a common passage, .such as the passage:I3"'opening outwardly of'the shank or holder.

We'claim'as our invention:

l. The method of securingadiamond or similar cuttingor abrading elementin a holder including the steps of forming in the holderia recess inwhich the element is to be'secured whileprojecting partially from therecess, partially embedding the element in the position it is ultimatelyto assumein a first temporary holding mediumlocated in the recess,embedding the remainder of the ele; m'ent ina second temporaryholdihgmedium carried by'the holder, removing the first temporary holdingmedium while the second temporary holding medium remains inpo'sition onsaid holdor and while the element is retained in position in the recessin the holder by the second temporary holding medium, and flowing intothe space created by removal of the first temporary holding medium apermanent holding medium 2. The method of securing a diamond or similarcutting orabrading element in a holder including thesteps of forming inthe holder a recess in which the element is to be secured-whileprojecting'lparti-ally fromthe recess, partiallyembedding .the elementin theposition it is ultimately'to assume ina first temporary holdingmedium 'located in the recess, embedding the remainder of the-element ina second temporary holding medium, removing-the first temporary holdingmedium while the second temporary holding medium man'ent holding medium,and removing the sec- 0nd temporary holding medium after the permanentholding medium has set. v

The method of secu'ring a-diamond or similar cutting or abrading elementina holder including thesteps of-formingin the holder arecess in-whichthe element is t be secured while projecting partially from the recess,partially filling the recess with a first temporary holding medium,partially embedding the element in" the holding medium in the positionit is ultimately to assume, embedding the remainder of the element in asecond temporary holding medium, removing the first temporary holdingmedium while the second term porary holding medium remains in positionon said holder and while the element is retained in position in therecess in the holder by the second temporary holding medium, and fiowinginto the space created by removal of the first temporary holding mediumpermanent holding medium.

4. The method of securing a diamond or similar cutting or abradingelement in a holder including the steps of forming in the holder arecess in which the element is to be secured while projecting partiallyfrom the recess, partially filling the recess with a first temporaryholding medium that is liquifiable and vaporizable byheat, partiallyembedding the element in the holding medium in the position it isultimately to assume, embeddin the remainder of the element in a secondtemporary holding medium, removing the first temporary holding medium bythe application of heat while the second temporary holding mediumremains in position on said holder and while the element is retained inposition in the recess in the holder by the second temporary holdingmedium, 1

and flowing into the space created by removal of the first temporaryholding medium a, permanent holding medium.

5. The method of securing a cutting or abrading element in a holderincluding the steps of forming in the holder a recess in which theelement is to be secured while project- 'ing partially from the recess,partially filling the recess with a first temporary holding medium thatis liquifiable and vaporizable by heat, partially 6. The method ofsecuring a diamond or similar cutting or abrading element in a holderincluding the steps of forming in the holder a recess in which theelement is to be secured while projecting partially from the recess,partially filling the recess with wax in a soft state, partiallyembedding the element in the wax in the position it is ultimately toassume and holding the element in and fiowing into liquify the firsttemporary diamond or similar cess the element is to be secured whileprojecting partiallyfrom the recess, forming in the holder a passagecommunicating at its inner end with said recess and opening outwardly ofthe holder at its other end, filling the recess with a first temporaryholding medium that is liquifiable by heat, embedding the element in theholding medium in the position it is ultimately to assume, embedding theremainder of the element in a second temporary holding medium, applyingheat to the holder to liquify the first temporary holding medium andpermitting the same to run off through the passage while the element isretained in position in the recess in the holder by the second temporaryholding medium, and feeding through the passage and into the spacecreated by removal of the first temporary holding medium a permanentholding medium.

8. The method of securing a diamond or similar cutting or abradingelement in a holder including the steps of forming in the holder arecess opening through a face of the holder in which recess the elementis to be secured while projecting partially from the recess, forming inthe holder a passage communicating at its inner end with said recess andopening outwardly of the holder at its other end, filling the recesswith a first temporary holding medium that is liquifiable by heat,embedding the element in the holding medium in the position it isultimatelyto assume, embedding the remainder of the element in a secondtemporary holding medium, applying heat to the holder to holding mediumand permitting the same to run off through the passage while the elementis retained in position in the recess in the holder by the secondtemporary holding medium, and pushing into the holder through thepassage a rod of a permanent metallic holding medium while the holder isstill hot.

9. The method of securing a diamond or similar cutting or abradingelement in a holder including the steps of forming in the holder arecess in which the element is to be secured while projecting partiallyfrom the recess, partiallyembeddin the element in the position it isultimately to as- I sume in a first temporary holding medium lothatposition until the wax sets, embedding the remainder of the element in acast of investment compound, applying heat to the holder to remove thewax while the investment compound remains in position on said holder andwhile the element is retained in position in the recess in the holder bythe investment compound, and flowing solder into the space created byremoval of the wax to hold the element permanently in position in theholder.

'1. The method of securing a diamond or similar cutting or abradingelement in a holder including the steps of forming in the holder arecess opening through a face of the holder in which recated in therecess, forming a mold about the end of the holder having the recesstherein, casting into the mold a, second temporary holding medium forembedding therein the remainder of the element, removing the firsttemporary holding medium while the second temporary holding mediumremains in position on said holder and while the element is retained inposition in the recess in the holder by the second temporary holdingmedium, and fiowing into the space created by removal of the firsttemporary holding medium a permanent holding medium.

10. The method of securing a diamond or similar cutting or abradingelement in a holder including the steps of forming in the holder arecess opening through a face of the holder in which recess the elementis to be secured while projecting partially from the recess, forming inthe holder a passage communicating at its inner end with said recess andopening outwardly ofthe holder at its other end, filling the recess witha first temporary holding medium that is liquifiable by heat, embeddingthe element in the holding medium in the position it is ultimately toassume, forming a mold about the portion of the holder having the recesstherein, casting in the mold a second temporary holding medium in. whichis embedded the remaining projecting portion of the element, applyingheat to the holder to reincluding I in the holder a recess in which acutting or abradwinding a strip of stiff tape about move the firstholding medium by flowing thereof through the passage while the elementis retained in position by the second temporary holding medium, andflowing through the passage into the space created by removal of thefirst temporary holding medium a permanent holding medium;

'11. The method of making a tool tipped with a diamond or similarcutting or. abrading element the steps of providing a holder, formingfirsttemporary holding medium while the second temporary holding mediumremains in position on said holder and while the element is retained inposition by the second temporary holding mecreated by removal of thefirst temporary holding medium a permanent holding medium.

13. The method of making a tool tipped with a shank, and a passageleading from near the bot recess radially outwardly and away the end ofthe shank to form a cup-like mold, casting in the mold a secondtemporary holding medium to emsecond temporary holding medium, andforcing into the passage an attenuated piece of solder including thesteps placing the element tially projecting position it is ultimately tohave and holding the-same until the compound sets,

holding medium is again completely filled firmly and rigidly to embedthe element in the shank.

14. The method of embedding a diamond or similar cutting or abradingelement in a holder of forming in the holder a recess in which theelement is to be secured, forming a passage communicating at its innerend with said recess and opening outwardlyof the holder, substantiallyfillingthe recess with a moldable and liquifiable compound in a softenedstate, in the compound in the parcasting a compound over the projectingportion of the element, removing the liquifiable compound and flowinginto the recess a metallic compound I while the element is held inposition in the recess in the holder by the cast compound.

15. The method of embedding a diamond or similar cutting or abradingelement in a holder including the steps of forming in the holder arecess in which the element is to be secured, forming a passagecommunicating at its inner end with said recess and opening outwardly ofthe holder, substantially filling the recess with a moldable andliquifiable compound in a softened state, placing the element in thecompound in the partially projecting position it is ultimately to haveand holding the same until the compound sets, forming about the end ofthe holder a mold projecting outwardly thereof, casting in the mold andabout the projecting portion of the element a non-metallic compound,removing the liquifiable compound'and flowing into the recess a metalliccompound while the element is held in position by the cast compound.

16. The method of making a tool tipped with a diamond or similarcuttingor abrading element including the steps of providing acylindrical shank, forming in the shank a plurality of generallylongitudinally extending recesses opening through one end of the shank,forming in the shank a passage opening at its outer end through the sideof said shank and extending inwardly and toward the end of said shankand communicating directly or through branch passages with saidrecesses, partially filling the recesses with a firsttempo-rary holdingmedium that is liquifiable and vaporizable by heat, the medium beingplaced in the recesses in a soft condition, partially embedding acutting or abrading element in the holding tape about medium in each ofthe recesses in the position it is ultimately to assume, winding a stripof stifi the end of the shank to form acuplike'mold encompassing all ofthe recesses, castng n the mold asecond temporary holding medium toembed therein the projecting portions of the elements, applying heat tothe shank while supported in an upright position to melt out and flowout through the passage and its branches the first temporary holdingmedium while the eleuntil the space created by removal of the first 70.

ments are retained in position by the second temporary holding medium,and forcing into the passage an attenuated piece of solder until thespaces created by removal of the first holding medium are againcompletely filled firmly and rigidly to embed each element in itsrecess.

JAN TAEYAERTS. MAGNUS 'TOELCKE.

